I just joined today for a specific problem with my dad's truck. It's a 2001 Sierra 2500 HD w/ the 6.6L Duramax. He had the injectors replaced last year under warrenty due to one cracking and leaking fuel into the crank case.

While towing (we have a 37' fifth wheel) and under load, the truck tends to throw a SES code, go into limp mode, and require the truck be shut off and sit for a few minutes before driving again. He used a code reader and got a "Massive Fuel Leak" code. He took it to the dealer and they decided the injectors were at fault again (this time the injector sleeves which they believe were not changed the last time). The job was just done last week.

Within 30 miles of having the truck back, it has the same problem. SES light, limp mode, shut it off for a bit. Now when he reads the codes, he gets a "Massive Fuel Leak" and a "Fuel Pressure Regulator" code. The dealer says that the FPR needs to be replaced but unfortunately the truck is out of warrenty.

Could the dealer replacing the injectors have possibly caused the FPR to fail? Could faulty injectors cause the FPR to fail? I would really like to pin this on the dealer considering the truck did not throw the FPR code before the dealer replaced the injectors but I can't rely on that.

If the dealer is not at fault, we plan to replace the FPR ourselves but I'm trying to locate some sort of documentation on its location. I have been told the FPR is located on the fuel pump but I was hoping someone would have a more detailed explanation on its replacement.

Thanks for any help.

Open search on the tool bar above. Lower right hand corner.
Type in Fuel Pressure Regulator
check Search Titles Only box
Look at post from Max OD on second page.
Open up fuel pressure regulator R&R instructions posted by Max Power on 6-5-2006
complete intructions with drawings. Also look at your low pressure fuel lines this would also be a good time to change them if they are showing any age.

Good price for parts at gmpartsdirect.com

Good Luck

Same symptoms here after injectors done. It would be easier to let the dealer change the FPR.

Same symptoms here after injectors done. It would be easier to let the dealer change the FPR.

Easier, yes. Less expensive, no.

Sure it would be easier but it would also cost $1200 to have them do it.

I appreciate the help. We're going to take a weekend and tackle it.

He's going to try some DieselKleen (I believe that's what it's called) and see if it cleans up the FPR and we won't need to replace it. Unfortunately, the part is already ordered. The dealership decided to order the part even though my dad never officially told them to. They were supposed to take a deposit of half the cost before ordering but never did.

Fortunately, I told the guy at the dealership that GMPartsDirect has it for much cheaper. He ran it through on GMPD and charged us what we would have been charged with shipping through GMPD. Ended up being $342 with shipping.

He heavily warned us about replacing it and wished us the best of luck. He said he doesn't like doing them when the problem comes up at the dealership.

Doesn't seem too difficult from the write-up.

Well my dad replaced the FPR this weekend. It took him about 9 hours by himself. I think that's pretty good for never doing it before. The stealership quotes the job at 7.5 hours and was impressed with his 9.

Unfortunately, replacing the FPR did not solve the problem. It did eliminate his surging idle but he still receives the P0093 code while putting a large load on the truck (towing up a hill). The injectors were just replaced under warrenty for the second time (thought to be the cause of the P0093 and the sleeves were beginning to fail), replaced the fuel filter, and replaced the FPR.

The dealership said the only other thing they think it may be is the fuel rail pressure sensor. My dad priced it out at ~$80 for the part but he's not sure about an accurate location or anything special he needs to do during replacement.

Do you guys think it's the sensor or could it possibly be something else?

I searched a bit and it looks like it might be a kink in the injection pump inlet hose as well.

My '01 Duramax with ~127k miles has done the same thing. The dealer replaced the injectors and the FPR at $122k but after about a couple of months, the problem came back. I took it to another dealer and today they called me telling me that injection pump is bad, only putting out ~17kpsi vs. about 22kpsi that is needed(?). $2200. I'm not sure where to go now. I'm been throwing money at this thing lately and it is getting stupid (hub bearings, axle seals, transfer case pump rub). I"m really starting to hate my D'max and dont think it was a good purchase. I expected a HD w/ a diesel to give me 200k miles w/o trouble and I can't get past 120k w/o essentially paying for a new small gas truck.

I expected a HD w/ a diesel to give me 200k miles w/o trouble and I can't get past 120k w/o essentially paying for a new small gas truck.

So did I.. Then at 104k miles, i spun a main bearing. I was without a truck for 3 months waiting for them to figure out what the problem was and then get it fixed. But i havent had any problem with it since then (except for that pesky fpr that's going out now :rolleyes:). Believe me, once you get the kinks worked out, you will love your truck ;).

99NightmareZ
Diesel Enthusiast

Do you have any kind of programmer or edge box?

Nope. The truck is completely stock. He has talked about getting a programmer/EDGE chip for it though.

The dealer replaced the injectors and the FPR at $122k

Now that is an expensive repair!:D

Sorry to hear you have had so many problems. I to have replaced a front hub, rear axle seals, (did them myself to save money, not that hard), Glow plugs and Injectors replaced under warranty or special policy. Have not had the pump rub, but watching it and may upgrade it this year just in case (again, doing it myself). Replacing the CP3 is involved but not hard from what I have read. Just takes time to get to it, change it out and get everything back together. Are they sure it is not the injectors again? I would push them to show you what they ran to come to that conclusion, but if it where me, I would replace it myself.

Well there's no certainty that is isn't the injectors again but they were just replaced 2 weeks ago. I sure hope it isn't them. :D Could have gotten a bad injector but I worry that he will have to pay another diagnostic charge ($200+) for them to decide it isn't the injectors again.

What's a general location of the fuel rail pressure sensor? Obviously on the rails but I was hoping for more specifics there. ;)

My story has gotten even more twisted. The dealer that diagonosed my problem as being the CP3 called back saying that they stopped their repairs because it appears to them that the injectors were never replaced. Now, I am caught in limbo waiting for a "district specialist" to determine if the new dealer can change them out or if it has to go back to the original dealer that supposedly installed them earlier. I am not a fan of Chevrolet right now. My truck sat for four days with nothing being done to it because of this while I had to get a rental car. I got fed up and took my truck back Friday night until they get their act together. I managed to get out of there without paying anything for now but they expected me to pay for a bunch of their time even though they haven't added any value to my truck.

Yes that was a typo, should have read 122k miles.

I used to do all my work myself but I am tied up in a never ending home remodeling job and just cant spend the time to work on vehicles now.

The 0093 code could be a bad fuel filter -- might consider changing it and open it up for inspection.:cool:

My dad just replaced the fuel rail pressure sensor this week and the truck is still throwing the same code. Here's a breakdown of what has been done:

- Fuel filter replaced
- Injectors replaced
- Fuel pressure regulator replaced
- Fuel rail pressure sensor replaced

Still throwing a P0093 code while under heavy load.

He is going to be dropping the fuel tank this Saturday to make sure the in-tank fuel screen isn't clogged. He is really hoping it isn't the fuel pump at this point.

Any ideas?

Looks like my dad decided to make a thread now.

http://www.dieselplace.com/forum/showthread.php?t=250142

Reference that for a more detailed explanation and current standing.